Catalytic Converter Replacement
Catalytic Converter Replacement (V8)
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle (Service and Repair).
2. Support the exhaust system near the resonator with a suitable jack.
3. Remove the oxygen sensor. It is not necessary to disconnect the electrical connector.
4. Remove the nuts securing the catalytic converter to the exhaust manifold pipe.
5. Remove the bolts securing the center exhaust hangers to the rear suspension support brackets.
6. Remove the catalytic converter from the manifold pipe.
7. Lower the exhaust system.
8. Remove the catalytic converter gasket (1). Do not reuse the gasket.
Important: Ensure the cut (1) is made 34 mm (1.3 in) from the weld on the intermediate pipe.
9. Cut the intermediate pipe 34 mm (1.3 in) from the resonator weld.
Installation Procedure
1. Slide 2 service clamps (1) over the catalytic converter assembly outlet pipe.
Do not tighten at this time.
Important: Ensure the O2 sensor boss is facing the right side of the vehicle.
2. Slide the catalytic converter assembly (1) outlet pipe over the intermediate pipe (2).
3. Place a NEW catalytic converter gasket over the catalytic converter studs.
4. Raise the exhaust system into position, aligning the catalytic converter with the exhaust manifold pipe.
5. Install the nuts securing the catalytic converter to the exhaust manifold pipe.
Do not tighten at this time.
Caution: Refer to Fastener Caution (Fastener Caution).
6. Install the bolts securing the center exhaust hangers to the rear suspension support brackets and tighten to 30 Nm (22 lb ft).
7. Tighten the catalytic converter nuts to 25 Nm (18 lb ft).
8. Remove the jack from under the vehicle.
9. Position the service clamps midway on the catalytic converter assembly outlet pipe, as close together as possible.
10. Rotate the clamps so the fastening ends are pointing in opposite directions and tighten to 54 Nm (40 lb ft).
11. Lower the vehicle.
12. Check the exhaust system for leaks.